Three-piece disposable undergarment with folded crotch member and method for the manufacture thereof

ABSTRACT

A disposable absorbent garment includes a front body panel having a first bodyside surface, a first garment side surface, a pair of opposite first side edges, a first waist edge and a first crotch edge defining a first lobe having a first profile in plan view that extends outwardly relative to the first waist edge. The first lobe has a first maximum rise along a first direction at substantially a centerline of the front body panel. The opposite first side edges are spaced along a second direction, with the second direction being substantially perpendicular to the first direction. A rear body panel has a second bodyside surface, a second garment side surface, a pair of opposite second side edges, a second waist edge and a second crotch edge defining a second lobe having a second profile in plan view that extends outwardly relative to the second waist edge. The second lobe has a second maximum rise along the first direction at substantially a centerline of the rear body panel. The opposite second side edges are spaced along the second direction. The first lobe of the front body panel is aligned with the second lobe of said rear body panel. A crotch member includes a base panel having opposite side edges and at least a pair of folds extending from the side edges of the base panel. The pair of folds are connected to the first and second garment side surfaces of the front and rear body panels respectively. The crotch member is aligned with and overlaps the first and second lobes of the front and rear body panels respectively on the first and second garment sides thereof. A method of manufacturing a disposable undergarment is also provided.

[0001] This application is a continuation-in-part of U.S. applicationSer. No. 10/261,805, filed Oct. 1, 2002, the entire disclosure of whichis hereby incorporated herein by reference.

BACKGROUND

[0002] The present invention relates generally to disposableundergarments, and in particular, to a three-piece undergarment having afolded crotch member and to the method for the manufacture thereof froma nested front and rear body panel web.

[0003] Disposable undergarments can be configured in many differentforms. For example, disposable absorbent garments can be configured as apant-type, pull-on garment, or as a diaper-type product that is drawn upbetween the legs and fastened about the waist with various fasteningsystems. Often, absorbent garments include an outer cover, which formsat least a part of a body panel that is secured around the waist of theuser. In addition, the outer cover typically extends along a crotchregion of the garment.

[0004] Often, the outer cover is made from a single piece of material,with leg openings cut therein, for example by die cutting. The materialfrom the leg cut out, which can account for as much as 20-30% of thetotal area of the outer cover, typically is waste material, which mustbe disposed of or recycled. In addition, the size of the leg openingsformed by a die cutter in a conventional one-piece outer cover istypically fixed. As such, it can be expensive and time consuming, andreduces the overall flexibility of the manufacturing line, to switchdies and alter the process to manufacture different size garments.

[0005] In response to this problem of waste, some garments areconfigured with front, rear and crotch sections formed from a single webthat is divided into two nested halves, as disclosed for example in U.S.Pat. No. 5,858,151 and Japanese Patent Application 03-176053 A. However,the webs of the U.S. Pat. No. 5,858,151 have overlapping crotch portionsthat are directly secured one to the other. Accordingly, the overallrise of the garment is not readily varied to accommodate different sizeusers, and the range of sizes is limited by the extent of theoverlapping regions.

[0006] Conversely, the diaper body of Japanese Patent Application03-176053 A is positioned over the cut-out portions of a front and backwaistband, such that the exposed portion of the waist bands defining inpart the leg holes are linear. Instead, the shape of the leg hole isdetermined by the cut shape of the diaper body, which produces excessmaterial that must be disposed of or recycled.

[0007] In addition, crotch members are often secured to the bodyside ofthe body panels or integrated therein, rather than being secured to thegarment side thereof. Accordingly, the body panels can restrict theexpansion of the crotch member, for example when an absorbent insert isinsulted by the user.

[0008] U.S. Pat. Nos. 6,217,563 and 6,264,641, the entire disclosures ofwhich are hereby incorporated herein by reference and which are bothassigned to Kimberly-Clark Worldwide, Inc., the Assignee of the presentapplication, disclose securing an expandable absorbent composite to agarment side of a pair of spaced apart body panels. The '563 and '641patents disclose that the inboard edges of the body panel are straightor curved, and in one particular arrangement are concave-inward.

[0009] In addition, the crotch member, which is often configured as anabsorbent insert, is typically not stretchable. Often, thenon-stretchable crotch member is secured across its entire width, so asto reduce or otherwise impede the elongation of the body panel andthereby adversely affecting its ability to conform to the body of theuser.

[0010] Therefore the need remains for improved methods and assembliesfor manufacturing undergarments to reduce the waste of materials whileproviding improved comfort for the user and flexibility in manufacturingdifferent size garments.

SUMMARY

[0011] Briefly stated, in one embodiment described below, a disposableabsorbent garment includes a front body panel having a first bodysidesurface, a first garment side surface, a pair of opposite first sideedges, a first waist edge and a first crotch edge defining a first lobehaving a first profile in plan view that extends outwardly relative tothe first waist edge. The first lobe has a first maximum rise along afirst direction at substantially a centerline of the front body panel.The opposite first side edges are spaced along a second direction, withthe second direction being substantially perpendicular to the firstdirection. A rear body panel has a second bodyside surface, a secondgarment side surface, a pair of opposite second side edges, a secondwaist edge and a second crotch edge defining a second lobe having asecond profile in plan view that extends outwardly relative to thesecond waist edge. The second lobe has a second maximum rise along thefirst direction at substantially a centerline of the rear body panel.The opposite second side edges are spaced along the second direction.The first lobe of the front body panel is aligned with the second lobeof said rear body panel. A crotch member includes a base panel havingopposite side edges and at least a pair of folds extending from the sideedges of the base panel. The pair of folds are connected to the firstand second garment side surfaces of the front and rear body panelsrespectively. The crotch member is aligned with and overlaps the firstand second lobes of the front and rear body panels respectively on thefirst and second garment sides thereof.

[0012] In one embodiment, the crotch member is substantially C-shaped incross-section. In another embodiment, side portions of the crotch memberare substantially Z-shaped in cross-section.

[0013] In one embodiment, the crotch member is formed as an absorbentinsert. The absorbent insert includes a top sheet, a back sheet and aretention portion disposed therebetween.

[0014] In another aspect, a method of manufacturing an undergarmentincludes moving a web of body panel material in a longitudinal machinedirection and cutting the web of body panel material along thelongitudinal machine direction to thereby form a rear body panel web anda front body panel web each having a maximum rise and a minimum riserespectively. The maximum rise of each of the rear and front body panelwebs is greater than the minimum rise of a corresponding one of the rearand front body panel webs. The method further includes shifting at leastone of the rear and front body panel webs in the longitudinal machinedirection and thereby aligning the maximum rises of the rear and frontbody panel webs. The method further includes centering a crotch memberwith the maximum rises of the rear and front body panel webs andconnecting the crotch member to a garment side surface of the front andrear body panels.

[0015] In one embodiment, the cutting of the web of body panel materialalong the longitudinal machine direction includes forming asubstantially sinusoidal pattern defining the maximum and minimum risesof each of the rear and front body panel webs.

[0016] In one embodiment, the front and rear body panel webs are cutalong the lateral cross direction proximate the minimum rise of each ofthe front and rear body panel webs. Also in one embodiment, the crotchmember is folded.

[0017] In another aspect, a die is used to cut the web of body panelmaterial. In one embodiment, the method includes forming a cut edgealong each of the front and rear body panel webs, wherein the cut edgesof the front and rear body panel webs have a first and second shaperespectively. In one embodiment, the first shape is different than thesecond shape.

[0018] In another aspect, the wave pattern defining the cut edges of thefront and rear body panel webs is not symmetrical relative to acenterline extending in the longitudinal machine direction. Inparticular, the curve defining the cut edge on one side of thecenterline has a different shape than the curve defining the cut edge onthe other side of the centerline. In one example, the curves, ifcontinuous on both sides of the centerline, would have a differentwavelength.

[0019] In another aspect, one embodiment further includes elongating theweb of body panel material in the longitudinal machine direction beforecutting the web of body panel web. In this way, the pitch of the garmentcan be easily changed simply by varying the amount of elongationintroduced into the web before the web is cut.

[0020] In yet another aspect, one embodiment of the method furtherincludes varying a gap formed between the maximum rises of each of therear and front body panel webs. In this way, the overall rise of thegarment can be easily changed simply by varying the gap.

[0021] In various embodiments, elastic elements are positioned along oneor more of the outer lateral edges of the inner cut edge of one or moreof the webs.

[0022] In another embodiment, the crotch member is formed of anelastic/stretchable material. In one particular embodiment, one or bothof a top sheet and backsheet, with a retention portion disposedtherebetween, are stretchable and include an elastic material.

[0023] In another aspect, a method includes stretching at least one ofthe back sheet and top sheet. In yet another aspect, a method includesinstructing a user on the user of a disposable undergarment is provided.

[0024] The various aspects provide significant advantages over otherdisposable undergarments and methods. For example and withoutlimitation, the nested body panels of one embodiment maximize the areaof body coverage while minimizing and virtually eliminating the amountof waste material. In addition, by securing the crotch member to thegarment side surface of the body panels and centering it over the lobes,a unique gasket system is created that maintains a close fit of thegarment to the body of the user while allowing the crotch member, e.g.,an absorbent insert, to expand outwardly from the skin. In addition, thelobes of the front and rear body panels provide a physical barrierbetween a wet absorbent insert and the skin of the user.

[0025] The foregoing paragraphs have been provided by way of generalintroduction, and are not intended to limit the scope of the followingclaims. The presently preferred embodiments, together with furtheradvantages, will be best understood by reference to the followingdetailed description taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026]FIG. 1 is a schematic illustration of a system for manufacturingan absorbent garment.

[0027]FIG. 2 is a plan view of a web of body panel material being cutalong a longitudinal machine direction.

[0028]FIG. 3 is a plan view of a front and rear body panel web with aplurality of absorbent inserts being applied thereto.

[0029]FIG. 4 is a plan view of one embodiment of an absorbent garment inan unfolded configuration.

[0030]FIG. 5 is a plan view of another embodiment of an absorbentgarment in an unfolded configuration.

[0031]FIG. 6 is a plan view of a web of body panel material being cutalong a longitudinal machine direction.

[0032]FIG. 7 is a plan view of a front and rear body panel web separatedin the cross direction and aligned in the machine direction.

[0033]FIG. 8 is a garment having a front and rear body panel web formedfrom the webs shown in FIG. 7.

[0034]FIG. 9 is a plan view of another embodiment of an absorbentgarment in an unfolded configuration.

[0035]FIG. 10 is a cross sectional view of the absorbent garment shownin FIG. 9 taken along line 10-10.

[0036]FIG. 11 is a cross sectional view of the absorbent garment shownin FIG. 9 taken along line 11-1 1.

[0037]FIG. 12 is an alternative cross-sectional view of the absorbentgarment shown in FIG. 9 taken along line 12-12.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

[0038] It should be understood that the term “longitudinal,” as usedherein, means of or relating to length or the lengthwise direction. Theterm “laterally,” as used herein means situated on, directed toward orrunning from side to side.

[0039] The term “bodyside” should not be interpreted to mean in contactwith the body of the user, but rather simply means the side that wouldface toward the body of the user, regardless of whether an undergarmentis actually being worn by the user and regardless of whether there areor may be intervening layers between the component and the body of theuser. Likewise, the term “garment side” should not be interpreted tomean in contact with the garments of the user, but rather simply meansthe side that faces away from the body of the user, and therefore towardany outer garments that may be worn by the user, regardless of whetherthe undergarment is actually being worn by a user, regardless of whetherany such outer garments are actually worn and regardless of whetherthere may be intervening layers between the component and any outergarment.

[0040] The term “machine direction” means the direction of flow as thevarious members and webs progress along the fabrication line andprocess. It should be understood that various separate members or webscan each be traveling in a machine direction, but with the variousmachine directions not necessarily being parallel or oriented in thesame direction. For example, a first component such as a web may betraveling a first machine direction, which is substantiallyperpendicular to the travel of another component, such as an absorbentinsert, in a second machine direction.

[0041] The term “cross direction” means the direction substantiallyperpendicular to the machine direction.

[0042] The term “downstream” means that one item is positioned moreclosely to the output or finished product end of the machine and/orprocess relative to another item. Conversely, the term “upstream” meansthat an item is positioned more closely to the input end of the machineor process relative to another item. For example, the output end isdownstream of the input end, and vice versa, the input end is upstreamof the output end.

[0043] The phrases “removeably attached,” “removeably attaching,”“removeably connected,” “removeably engaged,” “releasably attached,”“releasably connected,” or “releasably engaged,” and variations thereof,refers to two or more elements being connected or connectable such thatthe elements tend to remain connected absent a separation force appliedto one, both or all of the elements, and where the elements are capableof being separated upon the application of a separation force. Therequired separation force is typically beyond that encountered whilewearing the absorbent garment.

[0044] The phrases “fixedly secured,” “fixedly engaged,” “fixedlyattached,” “fixedly connected,” and variations thereof, refers to two ormore elements being connected or connectable such that they are notdisconnected or otherwise separated, and are not intended to beseparated or disconnected, during the normal operation and use of theabsorbent garment.

[0045] The term “web” refers to a continuous stream of material, whethermade from one or more layers or substrates, and regardless of whether itmay have non-continuous, discrete items disposed thereon.

[0046] The terms “connecting,” “coupled,” “attached,” and “secured,” andvariations thereof, broadly covers two or more items being directlyconnected one to the other, or by way of one or more intervening membersor components.

[0047] Referring to FIGS. 4, 5 and 9, an undergarment 2 includes afirst, front body panel 4 and a second, rear body panel 6. The term“body panel” refers to the portion(s) of the undergarment, whether madeof one or more layers or substrates or of one or more pieces orcomponents, that is/are fitted circumferentially around at least thewaist region of the user, including for example the user's lower back,buttock, hips and abdomen. The first and second body panels each have aninner, bodyside surface 10 and an outer, garment side surface 12. Thefirst, front body panel 4 has a first edge 14 forming a crotch portion16 and leg opening portion 18 and a second terminal edge 20 which, inone embodiment, is linear but can assume other shapes. Likewise, thesecond, rear body panel 6 has a first edge 22 forming a crotch portion24 and a leg opening portion 26 and a second terminal edge 28, which isshown linear but can assume other shapes. Each of the first and secondbody panels has an outboard side edge 30, 32 formed along the outerperiphery of the opposite side portions of the first and second bodypanel. It should be understood that the outboard side edges of the frontand rear body panels can have different lengths relative to each other.

[0048] Referring to FIG. 5, one or more, and in one embodiment aplurality, meaning two or more, elastic elements 36 are secured to eachof the first and second body panels. In preferred embodiment, aplurality of elastic elements are spaced across substantially the entirewaist portion of the front and rear body panel 4, 6, although they maybe spaced across a lesser length. For example, elastic elements canextend along the upper waist portion and along the lower terminal edgedefining in part a leg opening 34.

[0049] In one embodiment, the front body panel has a “non-elasticized”area wherein there are no elastic elements, or other elastic orelastomeric backing members, incorporated therein or making up anyportion of the thickness or cross-section of the body panel at thatarea. It should be understood, that in an alternative embodiment, one ormore separate waist bands, with or without elastic elements, can besecured to one or both of the rear and front body panels, preferablyalong the upper terminal edges 20, 28 thereof. Likewise, one or moreseparate leg bands can be secured to one or both of the rear and frontbody panels along the leg open portions 18, 26 adjacent the leg openings34. Alternatively, one or both of the body panels can be formed withoutany elastic elements as shown in FIG. 4.

[0050] The various waist and leg elastic elements can be formed fromrubber or other elastomeric materials. One suitable material is a LYCRA®elastic material. For example, the various elastic elements can beformed of LYCRA® XA Spandex 540, 740 or 940 decitex T-127 or T-128elastics available from E.I. duPont De Nemours and Company, having anoffice in Wilmington, Del.

[0051] Referring to the embodiments of FIGS. 4, 5, 9, 10 and 12, eachbody panel 4, 6 is formed as a composite, or laminate material,otherwise referred to as substrates or laminates, with the plurality ofelastic strands or an elastomeric substrate 204 sandwiched therebetween.In one embodiment, the elastic substrate is made of an elastomeric filmor nonwoven elastic or stretchable material including for example butnot limited to styrenic copolymers of polyisoprene, polybutadiene orpolyolefin, copolymers of polyolefins, natural or styrene butadienerubber, polyurethanes, polyamides, polyesters, and co-extrusions/blendsof the aforementioned materials. The elastic substrate or core can beformed as a membrane or from a plurality of elastic strands.

[0052] Preferably two or more layers 202 are bonded with variousadhesives, such as hot melt, or by other techniques, including forexample and without limitation ultrasonic bonding and heat pressuresealing. In one embodiment, the two layers are made of a non-wovenmaterial such as a spunbond material, a bonded carded material or otherknown materials. It should be understood that the body panels can bemade of a single layer or substrate of non-woven material, or can becomprised of more than two layers or substrates. Of course, it should beunderstood that other knitted or woven fabrics, non-woven fabrics,elastomeric materials, polymer films, laminates and the like can be usedto form one or more of the body panel layers. The term “non-woven” webor material, as used herein, means a web having a structure ofindividual fibers or filaments that are interlaid, but not in anidentifiable manner and without the aid of textile weaving or knitting,as in a knitted or woven fabric.

[0053] In one embodiment, the body panel material can be secured to theelastic elements, such as a elastomeric web, strands or ribbons, whichhave been elongated and retracted, such that the material is gatheredwhen the elastic elements are relaxed. Alternatively, the material canbe gathered and laminated to non-elongated elastic elements. In oneembodiment, the body panel includes a gathered elastic laminate madefrom nonwoven base sheets bonded with elongated elastic element(s)sandwiched therebetween.

[0054] In various embodiments, the body panel material may besubstantially permeable to air or substantially impermeable to air. Thebody panel material also may be substantially liquid-permeable orsubstantially liquid-impermeable. In particular arrangements, the bodypanel material may be substantially nonelastomeric. In other aspects,the body panels can include an elastomeric material that iselastomerically stretchable at least along the lateral article width.Examples of such elastomeric composite materials can include acontinuous filament stretch bonded laminate (CFSBL), a vertical filamentlaminate (VFL), neck-bonded-laminate (NBL), a stretch-bonded-laminate(SBL), a necked-stretch bonded laminate (NSBL) or a necked-thermallaminate, or the like, as well as combinations thereof. Exemplary CFSBL,NBL, SBL, and NSBL materials are described in U.S. Pat. Nos. 5,226,992,4,981,747, 4,965,122, 5,336,545, 5,385,775, 5,414,470, 4,720,415,4,789,699, 4,781,966, 4,657,802, 4,652,487, 4,655,760, 5,116,662,5,114,781 and 6,323,389, all of which are hereby incorporated herein byreference. Exemplary VFL materials are described in U.S. ProvisionalPatent Application Serial No. 60/204,307, filed May 15, 2000 andentitled “Method and Apparatus for Producing Laminated Articles,” andPCT application WO 01/88245 A2, both assigned to Kimberly-ClarkWorldwide, Inc., the Assignee of the present application, with theentire disclosures of both being hereby incorporated herein byreference. Such laminates can provide an improved combination ofcloth-like feel and elastomeric stretchability. The body panels can becomposed of materials that are elastic or elastomeric and exhibitbiaxial stretch characteristics or MD/CD stretch characteristics, orthat are extensible composites. Additional waist and leg elasticelements can be added to, but are not necessarily required by, the bodypanels.

[0055] In one embodiment, the entirety of the body panels areelasticized, such that the entire body panel conforms to the body of theuser without any spacing between the body panel and the user's body, andwithout the attendant bulkiness of a non-elasticized material.

[0056] In various embodiments, the body panels are breathable,cloth-like, multi-directional nonwoven laminates with stretch and/orextensible properties. In one embodiment, the non-woven layers arepre-necked, for example between about 10% and about 80%, in thelongitudinal direction, which provides extensibility in the longitudinaldirection with rminimum force.

[0057] The terms “extensible,” “extensibility,” and variations thereofas used herein means capable of being extended, and providing a selectedelongation, for example between about 5% and about 70%, when subjectedto an applied tensile force. The body panel also is preferably capableof providing a selected, sustained deformation when subjected to anapplied tensile force and then allowed to relax for a selected timeperiod beginning immediately after removal of the tensile force. Thesustained deformation is a substantially permanent deformation. Theselected elongation and sustained deformation preferably occur at leastalong the longitudinal direction of the garment, although it should beunderstood that it also could occur along the lateral direction, orboth. Various extensible materials, and other acceptable materials thatcan be used for the body panels are described for example in U.S. Pat.No. 6,217,563, issued Apr. 17, 2001 to Kimberly-Clark Worldwide, Inc.,the same Assignee as the present application, the entire disclosure ofwhich is hereby incorporated herein by reference.

[0058] The extensibility of the non-woven material provides an increasein surface area without the retractive force of elastomeric materials.In one embodiment, body panel is extensible in at least thecross-direction, or longitudinal direction, with the material providingan elongation of at least about 1 cm when subjected to a tensile forceof 11.8 grams per cm. In addition, the body panel provides asubstantially permanent deformation of at least about 20% when it issubjected to a tensile force of 19.70 grams per cm and is then allowedto relax under a zero applied stress for a period of 1 minute. Ofcourse, it should be understood that the body panel can also be madeextensible in the lateral direction. A suitable technique for generatinga representative tensile-load v. extension curve, and for determiningthe amount of elongation and/or retractive force parameters of a selctedcomponent or material can emply ASTM Standard Test Method D882 (TensileMethod for Tensile Properties of Thin Plastic Sheeting) dated December1995, with the following particulars. The “width” of the test samplewill be a cross-wise width which can be conveniently obtained from theproduct being tested, and is desirably about 2 inch (about 5.04 cm). Thetest sample width is perpendicular to the direction of the tensile forceapplied during the testing. With regard to the shown configurations, forexample, the test sample “width” generally corresponds to thelength-wise dimension of the component along the longitudinal directionof the article. The initial separation of the jaws of the tensile testeris 3 inches (7.62 cm), and the moving jaw is moved at a constant rate of50 mm/min. The moving jaw is stopped at an extension of 50 mm for aperiod of 10 sec, and then returned back to its initial startingposition at a rate of 50 m/min. The force-extention curve to thecomplete tension and retraction cycle can be recorded on a conventionalcomputer equipped with commercially available software, such asTestWorks for Windows, version 3.09, which is available from MTS SystemCorporation, a business having a location at 14000 Technology Drive,Eden Prairie, Minn. The obtained data is normalized and reported inappropriate units of force per unit length of sample “width” ( e.g.grams-force per inch, or Newtons per inch, or grams-force percentimeter, or Newtons per centimeter).

[0059] In one embodiment, the front and rear body panels 4, 6 are madeof nonwoven laminates of two layers of longitudinally extensible 0.60osy polypropylene spunbond material with elongated strands of Lycra®elastic sandwiched between the spunbond layers and thereafter adhesivelybonded. In particular, the body panel material is necked in the crossdirection. As used herein, the term “necked,” and variations thereof,refers to any material that has been constricted in at least onedimension by applying a tensioning force in a direction that isperpendicular to the desired direction of neck-down. Processes that maybe used to constrict a material in such a manner include, for exampleand without limitation, drawing processes. The elastics are thenelongated in the machine direction and secured to the body panelmaterial. The elastics are then allowed to retract so as to gather thenecked spunbond material in the lateral (machine) direction therebycreating an elastically gathered non-woven body panel with longitudinalextensibility. The term “gather,” and variations thereof, as used hereinmeans puckered, or contracted into folds or wrinkles, which should beunderstood as including micro-pleats.

[0060] In this way, the body panel can be elongated in both thelongitudinal and lateral direction to conform to the body of the userwhen the garment is applied thereto. In particular, as the user pullsthe garment up over their hips, the non-woven laminate body panelsstretch in the lateral direction while the leg regions of the front andrear body panels conform to the crotch and body lines of the user. Atthe same time, the body panel material extends in the longitudinaldirection to conform to the buttocks and stomach of the user. Theextensibility of the body panels follows the natural curvature of user'sbody to provide conformance thereto. As the body panel extends in thelongitudinal direction, the spacing between the laterally extendingelastic elements 36, incorporated in one embodiment, will increase.

[0061] In one embodiment, the body panel non-woven material issubstantially hydrophobic, which may optionally be treated with asurfactant or otherwise processed to impart a desired level ofwettability and hydrophilicity. In one particular embodiment of theinvention, the body panel is a nonwoven, wire-weave spunbondpolypropylene fabric composed of about 1.6 denier fibers formed into aweb having a basis weight of about 0.6 osy. One suitable non-wovenmaterial is the Corinth 0.60 osy, 1.6 dpf wireweave, nonwettableMetallocene (EXXON ACHIEVE 2854 PP) spunbond material manufactured byKimberly-Clark Corporation, the Assignee of the present application.

[0062] Referring to FIGS. 4 and 5, a crotch member 50 connecting thefront and rear body panels 4, 6 can be folded such that the side edges30, 32 of the front and rear body panels 4, 6 are aligned wherein theycan be fixedly secured at a seam. The seam can be formed by bonding,sewing or otherwise attaching the side edges. Alternatively, the productcan remain “open,” wherein the body panels are releasably secured withone or more fastening members as explained below.

[0063] In one embodiment the garment includes a combination of sideedges that are secured to form a seam and fastening members that allowthe fit of the undergarment to be adjusted. For example, fasteningmembers are preferably attached to the front body panel and extendinboard relative to the outboard side edge 30 of the front body panel 4from an attachment location, which is preferably spaced inboard from theside edge. A landing member can be formed on or secured to the bodypanel to receive a refastenable portion of the fastening member. One ormore lines of weakness can be provided along the front or rear bodypanel such that one or both of the body panels are breakable. The linesof weakness can comprise a perforation or other series of cuts, athinning, breakage or separation of material, or a strip of a differentkind of material bridging portions of the body panel that is more easilytorn or broken than the other material thereof, which allow a user orthe manufacturer to separate portions of the body panel. For example,the undergarment can be broken along the lines of weakness after thegarment is applied to a user, or beforehand.

[0064] It should be understood that, in other embodiments, the fasteningmembers can be secured to the rear body panel and engage the front bodypanel or, conversely, can be secured to the front body panel and engagethe rear body panel, for example along at least a portion that is notelasticized. In one embodiment, the fastening members are fixedlysecured to the outer, garment-side surface of the front and/or rear bodypanels, and releasably engage the outer, garment-side surface of thefront and/or rear body panels, although it should be understood that thefastening members could be fixedly secured to an inner body-side surfaceof front and/or rear body panels and releasably engage an inner,body-side surface of the front and/or rear body panels.

[0065] When incorporated into a disposable absorbent undergarment, inone embodiment, the fastening members include a refastenable portion,such as an array of hook members, adhesives, such as pressure sensitiveadhesives, buttons, zippers, snaps and other releasable and reattachablefastening devices. In various embodiments, the fastening member includesone, two or more than two tab members. In one embodiment, the fasteningmembers comprise a carrier member, which is preferably fixedly securedto the side portions of the front body panel with adhesive bonds, sonicbonds, thermal bonds, pinning, stitching or other known types ofattachment. In alternative embodiments, the fastening members can befixedly secured to the rear body panel or to one or both of the frontand rear body panels, for example, at the seam, as explained above.

[0066] Referring to FIGS. 4, 5 and 9, in one embodiment the undergarmentis disposable and is also configured as an absorbent undergarment. Inthe absorbent garment, the crotch member 50 is configured as anabsorbent insert having first and second opposed terminal end edges 60,62.

[0067] In various embodiments, shown in FIGS. 9-12, the absorbent insertcrotch member 50 preferably includes a substantially liquid permeabletopsheet 206, or liner, a substantially liquid impermeable barrier layeror backsheet 208, and an outer cover 210, which is made in oneembodiment of a non-woven material that provides a cloth-like feel. Theouter cover may be omitted in some embodiments. A retention portion 212is disposed or sandwiched between the topsheet and the backsheet, whichare connected. The topsheet, backsheet and other components of theabsorbent insert 50 can be joined for example with adhesive bonds, sonicbonds, thermal bonds, pinning, stitching or any other attachmenttechniques known in the art, as well as combinations thereof. Forexample, a uniform continuous layer of adhesive, a patterned layer ofadhesive, a sprayed pattern of adhesive or any array of lines, swirls orspots of construction bonds may be used to join the topsheet andbacksheet, or any of the other components described herein.

[0068] It should be understood that the term “absorbent insert” refersto any material or assembly capable of absorbing liquids or bodilyexudates, and may be comprised of a single material or component, forexample a retention portion, or can be formed as a composite of severalcomponents. It should also be understood that the term “crotch member”refers to any member made of any material, including for example andwithout limitation those described herein with respect to the bodypanels and absorbent inserts, and is not limited to absorbent insertsand/or materials. For example, the crotch member may be made of one ormore layers of a non-woven material.

[0069] In one embodiment, additional layers, including for example, asurge layer, are also preferably incorporated into the absorbent insert.Preferably, the surge layer does not run the entire length of theabsorbent insert and is shorter than the retention portion. The topsheetcan be indirectly joined to the backsheet by affixing the topsheet tointermediate layers, such as the surge layer or retention portion, whichin turn is affixed to the backsheet. The absorbent insert also mayinclude barrier cuffs, or leakage control shields, formed along theopposite longitudinally extending edges of the absorbent composite.

[0070] Referring to FIGS. 9-11, the absorbent insert has a base panel214 and a pair of folds 218 extending laterally inward from and joinedto the base panel 214 at opposite folded side edges 216. The pair offolds 218 and base panel 214 provide the absorbent insert with a C-shapeconfiguration in cross-section. The garment side 226 of the folds aresecured to the garment side 12 of the body panels 4, 6 at an attachmentlocation 220, for example adjacent a free edge 222 of the folds.Referring to FIG. 9, the attachment location can extend continuously andlongitudinally along the portion of the crotch member that overlaps thefront and rear body panels, or in other embodiments, the attachmentlocations can be configured as one or more discrete and spaced-apartattachment locations.

[0071] Referring to FIGS. 9-11, the folds 218 can be formed from anycombination of the top sheet 206, the backsheet 208, the outer cover214, retention portion 212, or any other component. For example, asshown in FIGS. 10 and 11, the folds 218 are formed from a combination ofthe topsheet 206, backsheet 208 and outer cover 214. In otherembodiments, only one of those components, e.g., the backsheet or topsheet, forms the fold, and in other embodiments, some subcombinationthereof forms the folds, for example the outer cover and backsheet butnot the top sheet or retention portion. It should be understood that theretention portion can also include folds that are interfolded with thefolds of the backsheet and top sheet. Each of the individual layers mayalso have an edge folded back over itself.

[0072] Referring to FIGS. 10 and 11, one or more longitudinallyextending crotch elastics 224 are disposed between and secured to thetopsheet and backsheet using various methods described above. The crotchelastics 224 extend along the sides of the crotch member and overlap inone embodiment a portion of the front and rear body panel, as shown inFIG. 9. The crotch elastics provide a gasket against the body of theuser.

[0073] It should be understood that any number of folds can extend fromthe base panel. For example, as shown in FIG. 12, the absorbent insert50 includes a pair of first folds 218 extending from opposite firstfolded edges 216 formed at the juncture with the base panel, and a pairof second folds 230 extending from opposite second folded edges 234formed at the juncture with the first folds. In this embodiment, abodyside surface 232 of the absorbent insert, and in particular thesecond folds, are secured to the garment side surface 12 of the bodypanels 4, 6. As with the embodiment of FIGS. 9-11, the first and secondfolds 218, 230 can be formed from any combination of the various layersof the absorbent insert, including the backsheet, the top sheet, theouter cover and the retention portion. In addition, crotch elastics 224,which can include in various embodiments one or more strands, aredisposed between two or more of the layers in one or both of the firstand second folds 218, 230. In the embodiment of FIG. 12, opposite sideportions 236 of the absorbent insert have a Z-shape in cross-section. Itshould be understood that other embodiments may include more than twofolds on each side of the absorbent insert. For example, each sideportion may be formed as a multi-pleated configuration. Alternatively,the absorbent insert may not have any folds, and may be formed from asingle layer, having a body side surface secured to the garment sidesurface of the body panels.

[0074] The backsheet is preferably liquid impermeable, but may be liquidpermeable, e.g., when an additional barrier layer is used with theretention portion. For example, in one embodiment, the backsheet can bemade from a thin plastic film, or other flexible, substantiallyliquid-impermeable material. As used herein, the term “flexible” means amaterial that is compliant and which will readily conform to the generalshape and contour of the body of the user. The backsheet preventsvarious bodily fluids and exudates from wetting or otherwisecontaminating various bedding or outer garments worn by the user overthe absorbent garment. In particular, the backsheet can include a film,such as a polyethylene film, having a thickness of from about 0.012 mmto about 0.051 mm.

[0075] In various constructions, the topsheet can include various wovenor nonwoven materials and laminates, which can be stretchable orextensible. In one embodiment, the top sheet is an extensible material.For example, the topsheet can be composed of a meltblown or spunbondedweb of desired fibers, and may also be a bonded-carded web. For example,the topsheet can be made of a substantially hydrophobic material, andthe hydrophobic material may optionally be treated with a surfactant orotherwise processed to import a desired level of wettability andhydrophilicity. In one particular embodiment of the invention, thetopsheet is a nonwoven, spunbond polypropylene fabric composed of about2.8-3.2 denier fibers formed into a web having a basis weight of about22 gsm and density of about 0.06 gm/cc. The fabric can be surfacetreated with an operative amount of surfactant, such as about 0.28%Triton X-102 surfactant. The surfactant can be applied by anyconventional means, such as spraying, printing, brush coating or thelike.

[0076] In various constructions, the backsheet can comprise a woven ornonwoven fibrous web layer, which is treated or constructed, partiallyor wholly, to impart the desired levels of liquid impermeability toselected regions that are adjacent to or proximate the absorbentretention portion. For example, the backsheet may include agas-permeable, nonwoven fabric layer laminated to a polymer film layerwhich may or may not be gas-permeable. Other examples of fibrous,cloth-like backsheet materials can comprise a stretch thinned or stretchthermal laminate material composed of a 0.6 mil (0.015 mm) thickpolypropylene cast film and a 0.7 ounce per square yard (23.8 gsm)polypropylene spunbond material (2 denier fibers). A material of thistype has been employed to form the outercover of a HUGGIES® UltratrimDisposable Diaper, which has been commercially available fromKimberly-Clark Corporation. The backsheet can provide the outercover ofthe article, particularly in the crotch region. Optionally, however, thearticle may include a separate outercover component member, as disclosedherein, which is additional to the backsheet. The outercover can bejoined, for example, to one or more of the absorbent composite and/orbody panels as explained above.

[0077] In one embodiment, the retention portion 212, and othercomponents, such as a transfer layer (not shown) and tissue layers (notshown), are free floating (unattached) between the back sheet 208 andthe top sheet 206, which are secured along only the peripheral edgesthereof. Alternatively, the retention portion, transfer layer and othercomponents are minimally attached to one or both of the back sheet 208and top sheet 206. For example, the retention portion can be secured tothe back sheet along an attachment location positioned along thelongitudinal centerline of the retention portion. Alternatively, or incombination with the back sheet connection, the transfer layer orretention portion can be minimally attached to the top sheet. In thisway, the retention portion 212, and other components, do not impede orsubstantially affect the lateral stretchability and extensibility of theabsorbent insert 50 and in particular the top sheet and back sheet, atleast one of which is secured to the body chassis.

[0078] In other embodiments, the top sheet is indirectly joined to thebacksheet by affixing the topsheet to intermediate layers, such as thesurge layer or retention portion, which in turn is affixed to thebacksheet. The absorbent insert also may include barrier cuffs, orleakage control shields, formed along the opposite longitudinallyextending edges of the absorbent composite.

[0079] In one embodiment, the back sheet 208 is a stretchable, elastic,liquid impervious member. Alternatively, the back sheet may be liquidpermeable, e.g., when an additional barrier layer is used with theretention portion. In one embodiment, the back sheet 208 is a laminatestructure made of a stretchable, elastic material, such as anelastomeric film, which is laminated to an extensible non-woven materiallayer. It should be understood that the backsheet can be formed from asingle layer or substrate or more than two layers or substrates. Variousbacksheet and topsheet materials are described in U.S. application Ser.No. 10/325,500, filed Dec. 19, 2002, entitled “Disposable UndergarmentWith A Strechable Absorbent Insert and Method For the Use Thereof,” andassigned to Kimberly-Clark Worldwide, Inc., the Assignee of the presentapplication, the entire disclosure of which application is herebyincorporated herein by reference.

[0080] The backsheet may include a micro-porous, “breathable” materialwhich permits gases, such as water vapor, to escape from the absorbentgarment while substantially preventing liquid exudates from passingthrough the backsheet. For example, the breathable backsheet may becomposed of a microporous polymer film or a nonwoven fabric which hasbeen coated or otherwise modified to impart a desired level of liquidimpermeability. For example, a suitable microporous film can be a PMP-1material, which is available from Mitsui Toatsu Chemicals, Inc., acompany having offices in Tokyo, Japan; or an XKO-8044 polyolefin filmavailable from 3M Company of Minneapolis, Minn. The backsheet may alsobe embossed or otherwise provided with a pattern or matte finish toexhibit a more aesthetically pleasing appearance.

[0081] In various configurations of the invention, where a component,such as the backsheet is configured to be permeable to gas while havinga resistance and limited permeability to aqueous liquid, the liquidresistant component can have a construction which is capable ofsupporting a selected hydrohead of water substantially without leakagetherethrough. A suitable technique for deternmining the resistance of amaterial to liquid penetration is Federal Test Method Standard FTMS 191Method 5514, 1978, or an equivalent thereof.

[0082] In one preferred embodiment, the backsheet is sufficientlyimpermeable to liquid and semi-liquid materials to substantially preventthe undesired leakage of waste materials, defined as exudates, includingfor example urine and feces. For example, the backsheet member candesirably support a hydrohead of at least about 45 centimeters (cm)substantially without leakage. The backsheet member can alternativelysupport a hydrohead of at least about 55 cm, and optionally, can supporta hydrohead of at least about 60 cm, or more, to provide improvedbenefits.

[0083] The backsheet and/or outercover also can be extensible. In onepreferred embodiment, the backsheet and/or outercover is capable ofproviding an elongation of at least about 1 cm when subjected to atensile force of 11.8 g/cm, and further provides a substantiallypermanent deformation of at least about 20% when subjected to a tensileforce of 19.70 g/cm and is then allowed to relax under a zero appliedstress for a period of 1 minute.

[0084] For example, the extensible member can be composed of a neckedfiber, a creped fiber, a micro-pleated fiber, polymer films or the like,as well as combinations thereof. The fabrics may be woven or nonwovenmaterials, such as spunbond fabrics. One example of a suitableextensible material is a 60% necked, polypropylene spunbond having abasis weight of about 1.2 osy.

[0085] As explained above, the backsheet and/or outercover also can beexpandable, for example when it has one or more folds, e.g., one or morez-folds (not shown), or can be both extensible and expandable. The termexpandable as used herein means to enlarge or to increase the extent orarea, lateral and/or longitudinal, thereof, e.g., by unfolding one ormore folds.

[0086] The retention portion is preferably made of an absorbentmaterial, which can be any material that tends to swell or expand as itabsorbs exudates, including various liquids and/or fluids excreted orexuded by the user. For example, the absorbent material can be made ofairformed, airlaid and/or wetlaid composites of fibers and highabsorbency materials, referred to as superabsorbents. Superabsorbentstypically are made of polyacrylic acids, such as FAVOR 880 availablefrom Stockhausen, Inc. of Greensboro, N.C. The fibers can be fluff pulpmaterials, such as Alliance CR-1654, or any combination of crosslinkedpulps, hardwood, softwood, and synthetic fibers. Airlaid and wetlaidstructures typically include binding agents, which are used to stabilizethe structures In addition, various foams, absorbent films, andsuperabsorbent fabrics can be used as an absorbent material. Variousacceptable absorbent materials are disclosed in U.S. Pat. No. 5,147,343for Absorbent Products Containing Hydrogels With Ability To SwellAgainst Pressure, U.S. Pat. No. 5,601,542 for Absorbent Composite, andU.S. Pat. No. 5,651,862 for Wet Formed Absorbent Composite, all of whichare hereby incorporated herein by reference. Furthermore, the proportionof high-absorbency particles can range from about 0 to about 100%, andthe proportion of fibrous material from about 0 to about 100%.Additionally, high absorbency fibers can be used such as Oasis type 121and type 122 superabsorbent fibers available from Technical AbsorbentLtd., Grimsby, Lincolnshire, United Kingdom.

[0087] The retention portion can be made of a single or dual layer ofabsorbent material, and can include various folds. The retention portionpreferably has an hour-glass shape with enlarged end regions.Alternatively, the retention portion can include a folded ormulti-layered configuration. The retention portion preferably has alength substantially equal to, or slightly shorter than, the length ofthe absorbent insert. The retention portion can include one or morebarrier layers attached to the absorbent material. In one embodiment, anupper tissue substrate is disposed adjacent the retention portion.Alternatively, a lower tissue substrate can be disposed adjacent anopposite side of the retention portion, or the tissue can completelyenvelope the retention position.

[0088] Referring to FIGS. 4 and 5, the opposite garment side of the endregions of the crotch member 50, and in particular, the outer, garmentside surface of the backsheet, are secured to the bodyside surface ofthe opposed crotch portions 16, 24 of the first and second body panels4, 6. It should be understood that in alternative embodiments, shown forexample in FIGS. 9-12, the crotch member 50, for example one or theother of the garment side or the body side thereof depending on thefolded configuration thereof, can be secured to the garment side surfaceof the first and second body panels. It should be understood that thecrotch member 50 can be secured using any of the methods of attachmentdescribed above, including for example various adhesives, stitching orother bonding methods. The crotch member can be secured to the bodypanels with any configuration of attachment lines, swirls, patterns,spots, etc., or can be a full and continuous attachment therebetween.

[0089] The entire portion of the crotch member 50 overlapping the bodypanels 4, 6 can be attached thereto, or the crotch member can beminimally attached to the body panels, for example by one or more linesof attachment formed along the centerline of the absorbent composite, oralong a line adjacent the crotch portions 16, 24 of the body panels, soas to allow the body panels to stretch from side to side and extend fromfront to back, or from the crotch to the waist.

[0090] Referring to FIGS. 1-8, the method for fabricating one or moreembodiments of the aforedescribed refastenable absorbent garment isillustrated. Referring to FIGS. 1,2, 6 and 7, a web 72 of body panelmaterial is cut in a longitudinal machine direction 74 to form a frontand rear body panel web 76, 78. Preferably, the web 72 is cut in asinusoidal wave pattern, which should be broadly interpreted as apattern having peaks 54, 154 and valleys 56, 156, with the patterngenerally defined by a pitch P and an amplitude A, A1. The pattern canbe formed of undulating curves or wave patterns, or can include or bemade entirely of various linear portions.

[0091] Each body panel web includes an outer lateral edge 80, 82 and aninner cut edge 84, 86. In one embodiment, shown for example in FIG. 3,the inner cut edges 84, 86 of the front and rear body panel webscorrespond, or mate such that they have the same shape and amplitude. Insuch an embodiment, no waste material is generated.

[0092] In an alternative preferred embodiment, shown in FIGS. 6-8, thewave pattern defining the first and second cut edges 84, 86 has a firstand second shape 102, 104 formed on opposite sides of a wave baseline100, which extends in the longitudinal machine direction approximatelyhalf way between the peaks 54, 154 and valleys 56, 156 of the cut edges.In this embodiment, the first shape 102 is different from said secondshape 104, with each shape having a different curvature. In particular,the first shape 102 has a first wavelength L1 and the second shape 104has a second wavelength L2. Preferably, the first wavelength L1 isgreater than the second wavelength L2. In this way, as shown in FIG. 8,the front body panel 4 can be provided with a different shape than therear body panel 6. For example, the undergarment can be configured as athong shaped undergarment with a relatively narrow rear body panel 6.

[0093] In another preferred embodiment, a die cutter 101 is used to cutthe web. The die cutter is configured to form inner cut edges 84, 86 onthe front and rear body panels having different shapes and amplitudes A,A1, as shown for example in FIG. 2. In such an embodiment, a minimalamount of waste material is generated, but it allows for the front andrear body panels to be specifically shaped to conform to the body of theuser. For example, the shape of the rear body panel web 78 cut edge 86can be provided with lesser amplitude Al than the amplitude A of thefront body panel web 76. In this embodiment, a minimal amount of wastematerial 42 is produced. In one embodiment, one of the body panels isformed with a wave pattern, or substantially sinusoidal cut edge, whilethe other is configured with a straight cut edge. In various alternativeembodiments, the cut edges can be formed by an oscillating cutter,slitters, water jets, lasers and other known cutting devices.

[0094] In the preferred embodiment, each of the front and rear bodypanel webs 76, 78 has a maximum rise (Max R), measured at the peak 54,154 and 30 forming crotch portion lobes 16, 24 (along the centerline ofthe garment), and a minimum rise (Min R), measured at the valley 56,156. The term “rise,” as used herein, means the measured distancebetween two edges, for example the outer edge 80, 82 and the inner cutedge 84, 86 of each of the front and rear body panel webs 76, 78respectively. The total rise of the garment is measured between theouter edges 20, 28 of the front and rear body panels, or body panelwebs, after the crotch member is connected thereto. Preferably, one orboth of the front and rear body panel webs are shifted in thelongitudinal machine direction, as shown to align the maximum rises, orpeaks 54, 154, of the front and rear body panels, which also results inthe alignment of the minimum rises, or valleys 56, 156, of the front andrear body panels. In a preferred embodiment, the maximum rises, defininglobes 16, 24 of the absorbent garment, have a profile in plan view thatextends outwardly relative to the waist edge 20, 28. As shown in FIG. 1,a first and second conveyor 101, 103 can simply be spaced apart so as toprovide for a longer travel for one of the front and rear body panelwebs 76, 78.

[0095] Referring to FIGS. 1 and 2, the front and rear body panel webs76, 78 are also separated, or shifted, outwardly relative to one anotherin the lateral cross-direction 94 so as to form a gap 88 between the cutedges 84, 86 of the front and rear body panel webs 76, 78 at the maximumrise formed at the respective peaks 54, 154. In various embodiments, thespacing between the cut edges at the maximum rise of the respectivefront and rear body panels (i.e., the closest spacing between the frontand rear body panels) is preferably between about 1% and about 90% ofthe total rise of the garment, more preferably between about 10% andabout 60% of the total rise of the garment, and most preferably betweenabout 20% and about 40% of the total rise of the garment. In addition,in various embodiments, the spacing between the cut edges at the maximumrise of the respective front and rear body panels is preferably betweenabout 10 mm and about 800 mm, more preferably between about 50 mm andabout 500 mm, and most preferably between about 100 mm and about 300 mm.In an alternative embodiment, the cut edges and the crotch portions ofthe front and rear body panels overlap, and can be secured one to theother. In such an embodiment, the panels can be separated slightly, orcan simply be shifted in the longitudinal direction without any lateralseparation.

[0096] In one embodiment, the front and rear body panel webs 76, 78 areseparated such that no portions of either web overlap each other. Forexample, and referring to FIG. 1, in one embodiment, a first pair ofrollers 106 can be angled or twisted to laterally spread the front andrear body panel webs 76, 78 a first amount before they are shifted inthe longitudinal machine direction. A second pair of rollers 108 can beangled or twisted to laterally spread the front and rear body panel webs76, 78 a second amount after they are shifted in the longitudinalmachine direction. Of course, it should be understood that the front andrear body panels can be first shifted in the longitudinal machinedirection the desired amount and then separated in the lateral crossdirection the entire desired amount, or they can also be first separatedin the lateral cross direction the entire desired amount and thenshifted in the longitudinal machine direction. In another embodiment,the portions of the lobes or peaks of the body panels overlap eachother.

[0097] After the body panel webs 76, 78 are aligned and separated,regardless of the order thereof, a plurality of crotch members 50, forexample absorbent inserts, are positioned in the lateral cross directionso as to bridge the gaps 88 between the body panel webs 76, 78 atsuccessive peaks 54, 154 or lobes 16, 24 where the maximum rises of thebody panel webs are aligned at the centerline of the absorbent garment.It should be understood that the term “gap” as used herein includes a“zero” distance between the respective cut edges, wherein the cut edgesabut but do not overlap. The crotch members 50 are secured to the bodypanel webs 76, 78 as explained above. It should be understood that thecrotch members 50 are secured in one embodiment to a bodyside surface90, 92 of the body panel webs 76, 78, although they can also be securedto the garment side thereof as explained above with respect to FIGS.9-12. In one embodiment, the crotch members, for example the absorbentinserts, are assembled offline and are then applied to the front andrear body panel webs 76, 78 as those webs are carried by a constructiondrum 110.

[0098] As shown in FIG. 1, the crotch member is preferably rotated usingan offset cam action rotator 112. The rotator includes a plurality oftransfer segments 126, which can have a vacuum applied thereto, thatengage the crotch member 50. Coupler arms 127 connect the transfersegments and a drive ring. The coupler arm 127 includes a cam end havinga cam follower that follows the profile of a cam mechanism. The profileof the cam mechanism can be readily changed to change the desired speedoutput and pitch of the crotch member. In one preferred embodiment, therotator is configured to accelerate the crotch member. If the successivecrotch members 50 are separated by a perforation, the transfer segment126 breaks the perforation as it engages one crotch member and movesaway from the next crotch member, which is engaged by a next transfersegment 126. The rotator rotates the end portion of the transfersegment, preferably approximately 90 degrees, about a radial axis, suchthat the crotch member is oriented in the machine direction as describedabove as the transfer segments are rotated about a horizontal axis 128.Alternatively, the landing material and fastener material are cut andseparated by the transfer segments. The rotator, and the method for theuse thereof, is further disclosed in U.S. Pat. Nos. 5,761,478,5,759,340, and 6,139,004, and U.S. patent application Ser. No.10/038,766, entitled “Apparatus For Applying Discrete Parts to A MovingWeb,” filed Jan. 2, 2002, all of which are assigned to Kimberly-ClarkWorldwide, Inc., the Assignee of the present application, and the entiredisclosures of all of which are hereby incorporated herein by reference.Alternatively, the subassembly can be rotated using a revolving transferroll as shown and described in U.S. Pat. No. 4,608,115, which isassigned to Kimberly-Clark Worldwide, Inc., the Assignee of the presentapplication, and which is hereby incorporated herein by reference in itsentirety.

[0099] Referring to FIGS. 1 and 4, after the crotch members 50 aresecured to the body panel webs 76, 78 across the gap 88, the assembly isconveyed on a conveyor 114 to a helical folder 116, wherein theundergarments, and in particular the crotch members, are successivelyfolded such that the front and rear body panel webs 76, 78 arepositioned in an overlapping, or overlying relationship, preferably withthe outer edges 80, 82 aligned. In various alternative embodiments, thebody panel webs 76, 78 can be secured, for example by bonding, along alateral cross direction at the area of minimum rise, or valleys 56, 156to form the side seam 48. The front and rear body panel webs 76, 78 arethen cut along the lateral cross direction along the seam 48 to form aplurality of discrete disposable undergarments, each having a front andrear body panel 4, 6. Alternatively, the front and rear body panel webs76, 78 can be first cut at the area of minimum rise, or valleys 56, 156,and the crotch member 50 thereafter folded. Various refastenablefastening members can be applied to the front and rear body panels 4, 6or front and rear body panel webs 76, 78 before or after the variouscutting and folding operations. In yet another preferred embodiment, asexplained above, the undergarment can be configured with side seamswhich secure the front and rear body panels, and refastenable fasteningmembers, which bridge lines of weakness formed in one or the other ofthe body panels.

[0100] The elastic elements 36 are preferably incorporated into the web72 of body panel material prior to cutting the web 72 to form the frontand rear body panel webs 76, 78. If leg elastics are desired, preferablythey are integrated into the web 72 along a pattern that will follow thecut edge 84, 86 on each of the front and rear body panel webs 76, 78. Ofcourse, it should be understood that the elastics could be secured tothe body panel webs after they are formed by the die cutter, or othercutting operation. In addition, the elastics can be non-continuous andintermittently spaced along the longitudinal direction such that theyare incorporated along only the leg opening portions 18, 26 of the bodypanel webs and body panels.

[0101] The pitch (P) of the undergarment can be easily and quicklyadjusted without the need to change over to new dies. The term “pitch”as used herein means the distance between any two adjacent things inseries, and in particular between the valleys 56, 156 or side edges 30,32 of the finished undergarment. In particular, the web 72 of body panelmaterial is simply stretched or elongated various predetermined amountsbefore it is cut to form the front and rear body panel webs 76, 78. Forexample, the largest waist/hip size is provided when the web 72 of bodypanel material is introduced into the cutting operation, or die cutter,with no elongation or stretch in the longitudinal machine direction. Thesmallest waist/hip size is provided when the web 72 of body panelmaterial is elongated or stretched to its maximum capability, such thatafter the cutting operation, the front and rear body panel webs 76, 78retract to form a garment having a smaller pitch (P) between thevalleys. In one preferred embodiment, the elongation of the body panelmaterial is between about 20% and about 400%, in a more preferredembodiment the elongation is between about 50% and about 300%, and in amost preferred embodiment the elongation is between about 100% and about200%. The final size or pitch of the undergarment is also determined bythe process and positioning of the side seams, and the distancetherebetween.

[0102] The rise (R) of the undergarment, measured between the outeredges 20, 28, also can be easily and quickly adjusted without the needto change over to new dies. In particular, the front and rear body panelwebs are simply spaced apart in the lateral cross direction varyingamounts, preferably with the gap being less than the length of thecrotch member. For example, for a smaller garment having a lesser rise,the front and rear body panel webs 76, 78 are spaced closer together,with a smaller gap 88 or by overlapping the body panels, than for agarment having a greater rise.

[0103] Preferably, the same crotch member 50 can be used in any of thegarments, regardless of the pitch and rise. In this way, the overallsimplicity and efficiency of the system and method is greatly improved,and there is no need to maintain inserts of different sizes ininventory, or to provide manufacturing capabilities to produce differentsize inserts. Indeed, the preferred embodiment of the method providesfor a system of manufacturing a three-piece disposable undergarment withminimal waste, while providing flexibility to manufacture different sizegarments at minimal cost.

[0104] In one use, the body panels 4, 6 are elongated, with theattendant application of a tensile force. At the same time, theabsorbent insert, which includes in one embodiment an extensible topsheet 206 and a stretchable/elastic back sheet 208, stretches orelongates with the body panels. The back sheet can be elongated in oneembodiment between about 20% and about 150%, in another embodimentbetween about 40% and about 125% and in another embodiment between about50% and about 100%. Since, in one embodiment, the retention portion 212is free floating, or alternatively is minimally attached to thestretchable top sheet and the stretchable/elastic back sheet, e.g.,along the longitudinal center line, the retention portion 212 does notrestrict the elongation of the back sheet 208 and top sheet 206, or theattached body panels 4, 6.

[0105] In another use, the folded configuration of the absorbent insert50 in combination with the absorbent insert being attached to thegarment side of the body panels, allows for the absorbent insert toexpand outwardly as it is insulted by the user. This expansion iseffected without affecting the fit to the body of the user. In addition,the lobes of the body panels 4, 6, which extend over portions of theabsorbent insert 50, provide a physical barrier between the absorbentinsert and the body of the user.

[0106] Although the present invention has been described with referenceto preferred embodiments, those skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention. As such, it is intended that the foregoingdetailed description be regarded as illustrative rather than limitingand that it is the appended claims, including all equivalents thereof,which are intended to define the scope of the invention.

What is claimed is:
 1. A disposable undergarment comprising: a frontbody panel comprising a first bodyside surface, a first garment sidesurface, a pair of opposite first side edges, a first waist edge and afirst crotch edge defining a first lobe having a first profile in planview that extends outwardly relative to said first waist edge, whereinsaid first lobe has a first maximum rise along a first direction atsubstantially a centerline of said front body panel, and wherein saidopposite first side edges are spaced along a second direction, saidsecond direction being substantially perpendicular to said firstdirection; a rear body panel comprising a second bodyside surface, asecond garment side surface, a pair of opposite second side edges, asecond waist edge and a second crotch edge defining a second lobe havinga second profile in plan view that extends outwardly relative to saidsecond waist edge, wherein said second lobe has a second maximum risealong said first direction at substantially a centerline of said rearbody panel, wherein said opposite second side edges are spaced alongsaid second direction, and wherein said first lobe of said front bodypanel is aligned with said second lobe of said rear body panel; and acrotch member comprising a base panel having opposite side edges and atleast a pair of folds extending from said side edges of said base panel,said at least said pair of folds connected to said first and secondgarment side surfaces of said front and rear body panels respectively,and wherein said crotch member is aligned with and overlaps said firstand second lobes of said front and rear body panels respectively on saidfirst and second garment sides thereof.
 2. The disposable undergarmentof claim 1 wherein said crotch member comprises an absorbent insert. 3.The disposable undergarment of claim 2 wherein said absorbent insertcomprises a top sheet, a back sheet and a retention portion disposedbetween said top sheet and said backsheet.
 4. The disposableundergarment of claim 3 wherein said at least said pair of folds areformed by at least one of said top sheet and said backsheet.
 5. Thedisposable undergarment of claim 1 wherein first and second crotch edgesare spaced apart with said first and second lobes having anon-overlapping relationship.
 6. The disposable undergarment of claim 1wherein said at least said pair of folds comprises a pair of first foldsextending inwardly from said side edges of said base panel.
 7. Thedisposable undergarment of claim 6 wherein said crotch member issubstantially C-shaped in cross-section.
 8. The disposable undergarmentof claim 6 wherein said pair of folds each have a garment side surfacesecured to said first and second garment side surfaces of said front andrear body panels.
 9. The disposable undergarment of claim 1 wherein saidat least said pair of folds comprises a pair of first folds connected tosaid side edges of said base panel and a pair of second folds connectedto said first folds along a pair of folding edges.
 10. The disposableundergarment of claim 9 wherein opposite side portions of said crotchmember are each substantially z-shaped in cross-section.
 11. Thedisposable undergarment of claim 1 wherein said first lobe defines afirst wave pattern and said second lobe defines a second wave pattern.12. The disposable undergarment of claim 11 wherein said first andsecond wave patterns are substantially the same.
 13. The disposableundergarment of claim 11 wherein said first and second wave patterns aredifferent.
 14. A disposable undergarment comprising: a front body panelcomprising a first bodyside surface, a first garment side surface, apair of opposite first side edges, a first waist edge and a first crotchedge defining a first lobe having a first profile in plan view thatextends outwardly relative to said first waist edge, wherein said firstlobe has a first maximum rise along a first direction at substantially acenterline of said front body panel, and wherein said opposite firstside edges are spaced along a second direction, said second directionbeing substantially perpendicular to said first direction; a rear bodypanel comprising a second bodyside surface, a second garment sidesurface, a pair of opposite second side edges, a second waist edge and asecond crotch edge defining a second lobe having a second profile inplan view that extends outwardly relative to said second waist edge,wherein said second lobe has a second maximum rise along said firstdirection at substantially a centerline of said rear body panel, whereinsaid opposite second side edges are spaced along said second direction,and wherein said first lobe of said front body panel is aligned withsaid second lobe of said rear body panel; and an absorbent insertcomprising a top sheet, a back sheet and a retention portion disposedbetween said top sheet and said back sheet, wherein said absorbentinsert comprises a base portion and a pair of folds connected to andextending from said base portion at a pair of opposite folded edgeswherein said absorbent insert is substantially C-shaped incross-section, wherein said absorbent insert overlaps at least a portionof said first and second lobes of said front and rear body panelsrespectively on said first and second garment sides thereof and whereinsaid pair of folds are connected to said first and second garment sidesof said front and rear body panels.
 15. The disposable undergarment ofclaim 14 wherein said pair of folds are formed by at least one of saidtop sheet and said backsheet.
 16. The disposable undergarment of claim15 wherein said retention portion is disposed only along said baseportion and does not any portion of said pair of folds.
 17. A method ofmanufacturing an absorbent garment comprising: moving a web of bodypanel material in a longitudinal machine direction, said web having abodyside surface and a garment side surface; cutting said web of bodypanel material along said longitudinal machine direction and therebyforming a rear body panel web and a front body panel web each having amaximum rise and a minimum rise respectively, wherein said maximum riseof each of said rear and front body panel webs is greater than saidminimum rise of a corresponding one of said rear and front body panelwebs; shifting at least one of said rear and front body panel webs insaid longitudinal machine direction and thereby aligning said maximumrises of said rear and front body panel webs; centering an absorbentinsert extending in a lateral cross-direction along said maximum risesof said rear and front body panels, wherein said absorbent insertcomprises a base panel having opposite side edges and at least a pair offolds extending from said side edges of said base panel; and connectingsaid pair of folds to said garment side surface of each of said frontand rear body panel webs.
 18. The method of claim 17 further comprisingseparating said rear and front body panel webs in a lateralcross-direction, wherein said maximum rises of each of said rear andfront body panel webs are spaced apart in said lateral cross directionand form a gap therebetween in a non-overlapping relationship.
 19. Themethod of claim 17 wherein said cutting said web of body panel materialalong said longitudinal machine direction comprises forming asubstantially sinusoidal pattern defining said maximum and minimum risesof each of said rear and front body panel webs.
 20. The method of claim17 further comprising cutting each of said front and rear body panelwebs along said lateral cross direction proximate said minimum rise ofeach of said front and rear body panel webs and thereby forming aplurality of discrete absorbent garments each having a front body paneland a rear body panel respectively, wherein each of said front and rearbody panels has opposite side edges.
 21. The method of claim 20 furthercomprising folding said absorbent insert and thereby positioning one ofsaid front and rear body panels in overlying relationship with the otherthereof.
 22. The method of claim 21 further comprising connecting saidside edges of said front and rear body panels.
 23. The method of claim17 further comprising folding said absorbent insert and therebypositioning one of said front and rear body panel webs in overlyingrelationship with the other thereof.
 24. The method of claim 23 furthercomprising cutting each of said front and rear body panel webs in saidoverlying relationship along said lateral cross direction proximate saidminimum rise of each of said front and rear body panel webs and therebyforming a plurality of discrete absorbent garments each having a frontbody panel and a rear body panel respectively.
 25. The method of claim24 further comprising connecting said overlying front and rear bodypanel webs at said minimum rise of each of said front and rear bodypanel webs.
 26. The method of claim 17 further comprising elongatingsaid web of body panel material in said longitudinal machine directionbefore said cutting said web of said body panel material.
 27. The methodof claim 17 wherein said absorbent insert comprises a back sheet, a topsheet and a retention portion disposed therebetween.
 28. The method ofclaim 17 wherein said crotch member is substantially C-shaped incross-section.